BE1028851A1 - RECYCLABLE MAT AND METHOD OF MANUFACTURING RECYCLABLE MAT - Google Patents

Abstract

The present invention relates to a recyclable carpet comprising a fabric, wherein the fabric comprises a series of weft yarns, substantially perpendicularly inserted into and interwoven with a series of warp yarns in one or more weaving patterns, and wherein the fabric comprises a first face and a second face opposite said first face, in which the weft yarns and the warp yarns consist essentially of 100% polyester (PES) or recycled polyester (rPET), and in which a warp yarn comprises at least one thread and at most four threads, each thread comprising at least twenty-five filaments and at most seventy-five filaments. The invention also relates to a method of manufacturing a recyclable carpet.

Description

RECYCLABLE MAT AND METHOD OF MANUFACTURING RECYCLABLE MAT

TECHNICAL FIELD The invention relates to a recyclable carpet. In a second aspect, the invention also relates to a method of manufacturing a recyclable carpet.

In a third aspect, the invention also relates to a recyclable carpet according to the first aspect, manufactured according to a method according to the second aspect.

PRIOR ART Carpets are well known as floor coverings and are often used to cover rooms in homes and offices and commercial buildings. Carpets are widely used, especially in offices and commercial buildings. Many people move on carpets every day. For this, the carpets must have a high resistance to wear. Furnishings can change frequently, especially in offices and commercial buildings. Coins can be used for different purposes. The carpets are therefore regularly replaced, which leads to a lot of waste. Carpets according to the state of the art are not or not easily recyclable.

A prior art carpet comprises loops of pile which are tufted into a fabric and attached to the underside of the carpet by means of a soft rubber layer. The soft rubber layer also acts as a spring and shock absorber to increase comfort and as an anti-slip layer to prevent the mat from sliding on a surface.

The disadvantage of such a rug is that the curls of the pile cannot withstand heavy loads. The bristles wear out quickly due to people frequenting the rug. Another disadvantage is that the pile and the fabric comprise different yarns, for example synthetic yarns for the pile and jute for the fabric. It is therefore more difficult to recycle the carpet because the pile threads and the fabric must be separated from each other. The use of the rubber layer is also disadvantageous to recycling. The rubber layer cannot be recycled together with the pile and fabric and must first be separated from the rest of the mat. For this, the rubber layer has to be peeled off from the underside of the carpet, which makes the recycling of a carpet according to the state of the art impractical and economically unprofitable.

The present invention aims to provide at least one solution to some of the problems or drawbacks mentioned above. SUMMARY OF THE INVENTION In a first aspect, the present invention relates to a recyclable carpet according to claim 1. The particular advantage of a carpet according to the present invention is that it comprises a fabric, in which the weft yarns and the warp yarns consist essentially of 100% polyester (PES) or recycled polyester (rPET) and a warp yarn comprises at least one yarn and a maximum of four yarns and a yarn comprises at least twenty-cina flaments and at most seventy-five flames. The fabric gives the carpet greater wear resistance than a tufted pile carpet, the pile of which is very susceptible to wear under heavy load. As the warp yarns comprise at least one yarn, comprising at least twenty filaments, the warp yarns are strong enough to give structural strength to the carpet and to ensure high wear resistance of the warp yarns. A maximum of four yarns, each yarn comprising a maximum of seventy-five filaments, is advantageous for a recyclable carpet that is still light enough to handle and flexible enough to roll up. Using a cloth eliminates the need for a rubber layer to secure the bristles. As the weft and warp yarns are essentially made of 100% polyester {PES} or recycled polyester {rPET), the carpet can be recycled as a whole without having to separate the weft and warp yarns . Preferred embodiments of the device are set out in claims 2-10. In a specific preferred embodiment, the invention relates to a device according to claim 2.

According to this preferred embodiment, at least one substrate is attached to a second face of the fabric, the substrate being suitable as an anti-slip and the substrate consisting essentially of 100% polyester. The substrate replaces the function of the rubber layer as non-slip. However, the substrate can be recycled together with the warp and weft yarns, so that it is not necessary to separate the substrate for the recycling of the warp and weft yarns as is the case with a layer rubber according to the state of the art. The substrate is further advantageous for improving the dimensional stability of the carpet.

In a second aspect. the present invention relates to a method according to claim 11. One of the advantages of this method is that a completely and easily recyclable carpet can be obtained by weaving, since the threads used for the warp and the weft are essentially made up of 100 % polyester (PES) or recycled polyester (rPET). Therefore, there is no need to separate the warp and weft yarns for recycling and these can be recycled together. An added benefit is that the rug is woven, which makes it a more hard-wearing rug than a pile rug. In addition, the warp yarns comprising a minimum of one yarn and a maximum of four yarns, each yarn comprising at least twenty-five filaments, are strong enough to impart structural strength to the carpet and to ensure high abrasion resistance of the yarns of chain. A maximum of four yarns, each yarn comprising a maximum of seventy-five filaments, is advantageous for a recyclable carpet that is still light enough to handle and flexible enough to roll up. Using a cloth eliminates the need for a rubber layer to secure the bristles. Preferred embodiments of the method are described in dependent claims 12 to 15.

In a third aspect, the present invention relates to a lapis according to the first aspect, manufactured according to a method according to the second aspect.

DESCRIPTION OF THE FIGURES Figure 1 shows a weaving pattern of a recyclable carpet according to one embodiment of the present invention.

Figure 2 shows a weave pattern of a recyclable carpet according to an alternative embodiment of the present invention. Figure 3 shows a weave pattern of a recyclable carpet according to another alternative embodiment of the present invention.

Figure 4 shows a schematic representation of a cross section of a recyclable carpet according to another alternative embodiment of the present invention.

DETAILED DESCRIPTION Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning generally understood by those skilled in the technical field of the invention. For a better evaluation of the description of the invention, the following terms are explicitly explained.

“un”, ’une”, “le” and “la” refer in this document to both the singular and the plural unless the context clearly suggests otherwise. For example, “a segment” means one or more than one segment.

The terms “comprising”, “comprising”, “composing of”, “composed of”, “intended to”, “behaving”, “comprising”, “containing” and “containing” are synonyms and are inclusive or open terms indicating the presence of the following, and not excluding or precluding the presence of other components, features, elements, members, steps, known or described in the state of the art.

Quoting numeric intervals by extreme values includes all whole numbers, fractions and/or real numbers between the extreme values, including those extreme values.

The term “weave pattern” is used here to refer to a specific manner and sequence in which the warp and weft threads are interwoven. The term “float” refers to a section of yarn appearing on the surface of the 5 woven carpet. The term "top float" refers to a section of yarn appearing at the top surface of the woven mat. The top surface is a side of the carpet that people walk on. A top float is formed by a bond pattern having a warp:weft bond density of 2:1, 3:1, 4:1, 5:1, 56 :1, 7:1, 8:1, 9:1, 10:1 or more. By this is meant that each weft thread floats on at least two warp threads, preferably at least 3 warp threads, etc. Alternatively, each warp yarn floats above at least two weft yarns, preferably at least 3 weft yarns, etc. The term “bottom float” refers to a section of yarn appearing at an underside of the woven mat. The bottom face is the face opposite the top surface and is configured to be placed on a floor surface. A bottom float is formed by a bonding pattern having a warp:weft bond density of 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10 or less. By this is meant that each weft yarn floats below at least two warp yarns, preferably at least three warp yarns, etc. Alternatively, each Warp Yarn floats under at least two weft yarns, preferably at least three weft threads, etc. The term “Haison” designates the interlacing of weft threads with warp threads to form a carpet. The term "weft float" refers to a float formed by a weft yarn. The term "warp float" refers to a float formed by a warp yarn.

The term “warp direction” indicates the direction according to the warp threads. The term “weft direction” refers to the direction according to the weft threads. The thread number refers to the thickness of the thread. The measurement is given as the ratio of the weight and the length of a piece of yarn. In weight numbering, the weight of a fixed length of yarn is determined. The length numbering determines the length of a fixed weight of yarn. Tex is an example of weight numbering where tex indicates the weight in grams of 1000m of yarn. The most commonly used is dtex, which gives the weight in grams of 10,000m of yarn.

In a first aspect, the invention relates to a recyclable carpet.

According to a preferred embodiment, the recyclable carpet comprises a fabric. The fabric comprises a series of weft yarns, essentially perpendicularly inserted into and interwoven with a series of warp yarns in one or more weaving patterns. The fabric includes a first side and a second side opposite the first side. The first side is configured as a use surface. The first side is the one that forms the visible surface after the installation of the recyclable carpet, on which people walk. The second face is the face configured to be placed on a floor surface in a room. The fabric is preferably a flat fabric.

The weft and warp yarns are essentially made of 100% polyester (PES) or recycled polyester (rPET). The warp threads include at least one thread and at most four threads. Each yarn contains at least vinat-five flaments and a maximum of seventy-five filaments. By including at least one fit, comprising at least twenty-five filaments, the warp yarns are strong enough to impart structural strength to the rug, in particular structural strength in the direction of the warp, and to provide high weather resistance. warp yarn abrasion. A maximum of four yarns, each yarn comprising a maximum of seventy-five flaments, is advantageous for a recyclable carpet that is still light enough to handle and flexible enough to roll up. The weave gives the carpet greater wear resistance than a low pile carpet, the pile of which is very susceptible to wear when heavily loaded.

An additional advantage of a weave over a tuite rug is that it does not require a backing such as fabric or needle felt to secure the pile, nor an additional layer of rubber to secure the pile to the backing. This is advantageous because it results in a lighter rug than a tufted pile rug, which is structurally strong due to the warp yarns. Because the weft yarns and the warp yarns consist essentially of 100% polyester (PES) or recycled polyester (rPET), it is particularly advantageous that the carpet can be recycled as a whole without the need for separating the weft or warp threads from each other and/or from a rubber layer.

According to a preferred embodiment, at least one substrate is attached to the second face of the fabric. The substrate is suitable as an anti-slip. The substrate thus replaces a layer of rubber as anti-slip. This is an advantage as it prevents a recyclable mat from slipping when used on a floor surface. The substrate is further advantageous for the dimensional stability of the recyclable carpet. The substrate is essentially made of 100% polyester. This is particularly advantageous because it allows the recyclable carpet to be recycled in a single step. There is no need to separate the substrate from the fabric when recycling. This makes the recyclable carpet convenient and economically profitable to recycle. The substrate is preferably made from a composition which is applied to the second side of the fabric. The composition is applied to the second face in the liquid state. The composition is a polyester forming composition.

According to another embodiment, the substrate is a foam. This is advantageous because it gives the substrate an elastic and cushioning effect, which makes the recyclable carpet comfortable to walk on.

Preferably, as in the case of an embodiment described above, the substrate is made from a composition, the composition comprising foaming additives.

According to another embodiment, at least one membrane is attached to the second face of the fabric. The membrane is essentially made of 190% polyester. The membrane is advantageous for the dimensional stability of the recyclable carpet. The membrane is attached to the fabric with polyester glue. This embodiment is particularly advantageous because it makes it possible to recycle the recyclable carpet in a single step. It is not necessary to separate the membrane from the fabric when recycling. This makes the recyclable carpet convenient and economically profitable to recycle.

According to another alternative embodiment, at least one second fabric is attached to the second face of the fabric. The second fabric includes weft and warp yarns essentially made of 100% polvester. The second fabric is advantageous for the dimensional stability of the recyclable carpet. The second fabric is attached to the fabric with polyester glue. This embodiment is particularly advantageous because it still makes it possible to recycle the recyclable carpet in a single step.

It is not necessary to separate the second fabric from the first when recycling. This makes it possible to recycle the recyclable carpet in a practical and economically profitable way.

According to a preferred embodiment, a warp yarn has a yarn number of at least 100 dtex and at most 600 dtex. A warp yarn having a yarn number according to this embodiment is advantageous in that it provides a fabric with strong warp yarns, structurally strong in the direction of the warp and heavy enough to prevent the recyclable carpet from sagging. curl, bend or deform under load. Preferably, a warp yarn has a yarn count of at least 110 dtex, more preferably at least 120 dtex, even more preferably at least 130 dtex and even more preferably at least 140 dtex.

Preferably, a warp yarn has a yarn count of at most 550 dtex, preferably at most 500 dtex, more preferably at most 450 dtex and more preferably at most 400 dtex.

According to one embodiment, at least some of the weft yarns comprise at least one yarn and at most four yarns, each yarn comprising at least twenty-five filaments and at most seventy-five filaments. By comprising at least one yarn, comprising at least twenty-five filaments, the weft yarns are strong enough to impart additional structural strength to the carpet depending on the direction of the weft and to provide high abrasion resistance to the yarns of frame. A maximum of four yarns, each comprising a maximum of seventy-five flaments, is advantageous for a recyclable carpet that is still light enough to handle and flexible enough to roll up. According to another embodiment, a weft yarn has a yarn number of at least 100 dtex and at most 600 dtex.

Preferably, a weft yarn has a Til number of at least 110 dtex, more preferably at least 120 dtex, even more preferably at least 130 dtex and even more preferably at least 140 dtex.

Preferably, a weft yarn has a yarn number of at most 550 dtex, preferably at most 500 dtex, more preferably at most 450 dtex and more preferably at most 400 dtex.

This embodiment has advantages similar to an embodiment described previously, in which a warp yarn has a yarn count of at least 100 dtex and at most 600 dtex. According to one embodiment, at least a part of the weft yarns are chenille yarns, A chenille yarn has a central component and a discontinuous component, The central component comprises one or more fllaments or yarns which are mechanically interwoven. The discontinuous component includes a plurality of wires connected to the central component. The discontinuous component extends outward from the central component. The softness of chenille yarn makes the use of chenille yarns as weft yarns give a specific look to recyclable carpet.

Preferably, at least 50% of the weft yarns are chenille yarns, more preferably at least 60%, even more preferably at least 70% and even more preferably at least 80%.

According to another embodiment, a chenille yarn has a yarn number of at least 2500 dtex and at most 6500 dtex. A chenille yarn with a yarn number according to this embodiment is advantageous in that it yields a fabric with sturdy chenille yarns, which is structurally strong in the weft direction and which is heavy enough to prevent the recyclable carpet from curl, bend or deform under load.

Preferably a fi! chenille has a yarn count of at least 3000 dtex, more preferably at least 3500 dtex, even more preferably at least 4000 dtex and even more preferably at least 4500 dtex.

Preferably, a chenille yarn has a yarn number of at most 6000 dtex, preferably at most 5500 dtex, more preferably at most 5000 dtex and more preferably at most 4700 dtex.

Preferably, the discontinuous yarns are yarns whose yarn count is at least 100 dtex and at most 400 dtex.

Preferably, a staple yarn has a yarn count of at least 110 dtex, more preferably at least 120 dtex, even more preferably at least 130 dtex and even more preferably at least 140 dtex.

Preferably, a staple yarn has a yarn count of at most 350 dtex, preferably at most 300 dtex, more preferably at most 250 dtex and more preferably at most 200 dtex.

The discontinuous threads are preferably tied to the central component.

According to one embodiment, at least part of the weft yarns are fancy yarns. Bouclé yarns and crimped yarns are non-limiting examples of novelty yarns. Preferably, a maximum of 50% of the weft yarns are fancy yarns, more preferably a maximum of 40%, even more preferably a maximum of 30% and even more preferably a maximum of 20%. Fancy yarns are advantageous to give a specific character to a recyclable carpet. It is obvious to a person skilled in the art that a recyclable carpet according to the present invention can comprise weft yarns, comprising at least one yarn and at most four yarns, each yarn comprising at least twenty-five filaments and at most seventy-five filaments, and/or chenille yarns and/or novelty yarns. According to one embodiment, the warp and weft yarns are colored. This is advantageous for obtaining a recyclable carpet in which the warp and weft yarns form a design thanks to one or more weaving patterns. According to an alternative embodiment, the warp and weft yarns are not colored. This is advantageous to obtain a recyclable carpet as an intermediate product, which can serve as the basis for various final products.

According to another embodiment, the recyclable mat is printed. A printed recyclable carpet is advantageous for quickly obtaining different designs from a single basic intermediary. According to a preferred embodiment, the recyclable mat comprises a label, which is essentially made of 100% polyester. This is advantageous because it allows a label to be recycled along with the recyclable carpet fabric.

The label is preferably self-adhesive. To this end, the label comprises a thermofusible layer. The label consists of a textile layer. The textile layer is preferably a polyester satin. The tag weight is at least 150 g/m², preferably at least 175 g/m², more preferably at least 200 g/m². and even more preferably at least 225 g/m°. The label weight is 350 g/m2 maximum, preferably 325 g/m? maximum, more preferably 300 g/m? maximum and even more preferably 275 g/m? according to a preferred embodiment, the recyclable carpet comprises at least 10 weft threads per cm and at most 30 weft threads per cm. This is advantageous because the carpet has enough weft yarns in the warp direction to form a strong fabric, while the fabric is still light enough to handle and soft and rollable enough. According to a preferred embodiment, the recyclable carpet comprises at least 15 warp threads per cm and at most 75 warp threads per cm. This is advantageous because the carpet has enough weft yarns in the weft direction to form a strong fabric, while the fabric is still light enough to handle and flexible and rollable enough. According to a preferred embodiment, an edge of the recyclable mat is scalloped. Scalloping is the process of providing a border by means of thread. Preferably, the recyclable mat is scalloped all around. The edge is scalloped with a yarn that is essentially 100% polyester. The scalloping is advantageous for the strength of the recyclable carpet and to prevent it from fraying at the edge. Using a yarn that is essentially 100% polyester is advantageous for recycling because there is no need to separate the yarn from the recyclable carpet when recycling.

According to a preferred embodiment, a woven strip is sewn to one edge of the recyclable mat. The woven band comprises weft and warp threads essentially made of 100% polyester. The woven strip is sewn to the recyclable mat with a thread that is essentially 100% polyester. The woven strip is sewn in a U-shape on the edge of the recyclable mat, a first leg of the U being located on a first face of the mat and a second leg of the U being located on a second face of the mat. The woven band is advantageous for the strength of the recyclable mat and to prevent it from fraying at the edge of the recyclable mat. Using a substantially 100% polyester yarn is advantageous for recycling because the yarn does not have to be separated from the recyclable carpet when recycling.

According to another embodiment, the edge of the recyclable mat is folded over and sewn. The edge is sewn with a compound thread essentially made of 100% polyester. Using a yarn that is essentially 100% polyester is advantageous for recycling because the yarn does not have to be separated from the recyclable carpet when recycling. Folding and stitching the edge of the recyclable rug is advantageous for visually concealing the woven strip. According to a preferred embodiment, the ratio between the mass per meter of a weft yarn and the mass per meter of a warp yarn is at least 5 and at most

15. A ratio according to this embodiment is advantageous to obtain a recyclable carpet with a structural strength both in the direction of the warp and in the direction of the weft which is not necessarily equal, but sufficiently similar, so that the Recyclable carpet is dimensionally stable. In this context, dimensional stability means that the proportions of the dimensions in the weft direction and the warp direction of the recyclable carpet remain the same within a margin of +10% under load. According to one embodiment, the weaving pattern is interrupted at least once to make visible at least a part of at least one warp thread on one of the faces of the recyclable mat. This part has a distance D which is longer than a distance d of a visible warp thread in which the weft threads are inserted and interwoven with the warp threads according to this weaving pattern. The distance d of a visible warp yarn refers to the distance the warp yarn extends when positioned above the weft yarns in a weaving pattern. The visible parts of the warp yarns are grouped with the distance D at the level of at least one zone of a face of the recyclable carpet. The segments extend the different distances from each other and over distances greater than the distance d defined by the weaving pattern. This embodiment is advantageous in that the recyclable carpet has a worn appearance, while the recyclable carpet is still structurally sound and has high wear resistance.

According to another embodiment, the weaving pattern is interrupted at least once to create at least one seam. This joint is a dividing line between two areas of the recyclable carpet each having a different appearance and a plurality of parts made of warp yarns, in which these parts have a distance D which is longer than a distance d of a yarn visible warp using the weaving pattern. The distance d of a visible warp yarn refers to the distance the warp yarn extends when positioned above the weft yarns in a weaving pattern. This embodiment is advantageous in that the recyclable carpet has a patchwork appearance, while the recyclable carpet is still structurally sound and has high wear resistance.

According to another embodiment, the recyclable mat comprises one or more zones having mainly upper or lower floats, thus forming respectively a high or a low relief. This embodiment is advantageous insofar as the recyclable carpet comprises multiple relief areas, while the recyclable carpet is structurally strong and has a high resistance to wear.

According to another embodiment, the recyclable mat comprises wide floats and narrow floats. The length of wide floats is between 4 and 6 mm and the length of narrow floats is between 1.5 and 2.5 mm. This embodiment is advantageous in that the recyclable carpet has a vintage look, while the recyclable carpet is still structurally sound and has high wear resistance.

In a second aspect, the invention relates to a method of manufacturing a recyclable carpet.

According to a preferred embodiment, the method comprises the following steps: - inserting warp threads into a weaving frame side by side without overlapping: - inserting and weaving the weft threads into the warp threads to forming a fabric such that the weft yarns are arranged in successive rows substantially perpendicular to the warp yarns, the weft yarns being repeatedly inserted in the same manner in one or more predetermined weaving patterns, and the fabric comprising a first face and a second face opposite this first face.

The fabric includes a first side and a second side opposite the first side. The first side is configured as a use surface. The first side is the one that forms the visible surface after the installation of the recyclable carpet. The second side is the one that is configured to be installed on the floor surface of a room. The fabric is preferably a flat fabric. The weft and warp yarns are essentially made of 100% polyester (PES) or recycled polyester (rPET). The warp yarns comprise at least one yarn and at most four ijs, each yarn comprising at least twenty-five flaments and at most seventy-five flaments. By comprising at least one yarn, composed of twenty-five filaments, the warp yarns are strong enough to impart structural strength to the recyclable carpet, in particular structural strength in the warp direction, and high abrasion resistance warp threads. A maximum of four yarns, each yarn comprising a maximum of seventy-five filaments, is advantageous for a recyclable carpet that is still light enough to handle and flexible enough to roll up. The weave gives the carpet greater wear resistance than a tufted pile carpet, the pile of which is very susceptible to wear when heavily loaded. An additional advantage of a fabric over tufted carpet is that there is no need to use a backing, such as fabric or needled felt, through which the pile is pierced, and it does not It is not necessary to apply an additional layer of rubber to secure the bristles in the holder. This method is advantageous because it results in a lighter rug than a tufted pile rug, which is structurally strong thanks to the warp yarns. The fact that the weft yarns and the warp yarns consist essentially of 100% polyester (PES) or recycled polyester (rPET) is particularly advantageous, because the carpet can be recycled as a whole without having to separate the weft yarns or the warp threads from each other and/or from a rubber layer.

According to a preferred embodiment, the method comprises the additional step of applying a composition to the second side of the fabric for the formation of a non-slip substrate consisting essentially of 100% polyester, the composition being a polyester-forming composition. The composition is preferably applied in the liquid state. The substrate is suitable as an anti-slip. The substrate replaces a layer of rubber as an anti-slip. This is advantageous because it prevents a recyclable rug from slipping when used on a floor. The substrate is further advantageous for the dimensional stability of the recyclable carpet. As the form substrate is essentially made of 100% polyester, the recyclable carpet can be recycled in a single step in a practical and economically profitable way.

According to another embodiment, the composition is applied to the second face of the fabric by means of a lick roller. The recyclable mat is guided along a rotating lick roller with the second side of the fabric. The excess composition is scraped from the second face of the fabric using a squeegee. Depending on the amount of composition needed to obtain a sufficiently strong substrate, the application parameters of the composition are adjusted. If more composition is required, the lick roller is pressed more strongly against the fabric of the recyclable mat. If more composition is required, more composition is fed into a reservoir in which the lick roller is positioned, causing the lick roller to pick up more composition from the reservoir during rotation of the lick roller and transfer it to the second side of the fabric. If more composition is required, the relative velocity between the lick roller and the recyclable carpet fabric is lower, allowing more time for the composition to transfer from the lick roller to the second side of the fabric. The relative speed can be varied by adjusting the speed of the licking roller or by rotating the licking roller in the same direction or in the opposite direction to the direction in which the fabric is moving. According to another embodiment, the composition is foamed on the second face of the fabric.

According to a preferred embodiment, the method comprises the additional step of drying the substrate at a temperature of at least 110°C and at most 170°C. The drying of the substrate makes it possible to evaporate the water from the composition and to initiate the polymerization. Drying firmly anchors the substrate to the second side of the fabric. The substrate is preferably dried at a temperature of at least 120°C and maximum 165°C, more preferably at least 130°C and maximum 160°C, and even more preferably at least 140°C and 155°C maximum. At these temperatures, the recyclable carpet is not damaged following drying.

According to one embodiment, the substrate is dried using a drying drum. A drying drum is a rotating drum with a heated surface. After application of the composition, the fabric is passed with the second side over a rotary drying drum. A drying drum is advantageous because the drying can be carried out in a continuous process. According to one embodiment, the substrate is dried using an oven, in which the oven has a longitudinal direction and in which the fabric moves through the oven in the longitudinal direction. This method is advantageous because it allows the drying to be carried out in a continuous process. The oven preferably has a length of at least 10 m, more preferably at least 15 m and even more preferably at least 20 m. The fabric is preferably guided by rollers, the fabric performing a rocking motion, transversely to the longitudinal direction of the oven. This extends the residence time of the fabric in the oven. |! It is obvious to a person skilled in the art that the drying can be done by combining a drying drum and an oven.

According to a preferred embodiment, the composition has a viscosity of at least 900 mPa.s and at most 2200 mPa.s and a density of at least 0.7 g/cm? and a maximum of 1.3 g/em°. A viscosity within the specified range is advantageous to prevent the composition from running off the fabric after the second side of the fabric has been applied, while a density within the specified range ensures that the composition is sufficiently diluted to be applied in the liquid state on the second side of the fabric.

According to one embodiment, the composition comprises foaming additives. The advantage is that a foam substrate is thus formed, giving the substrate an elastic and cushioning effect and making the recyclable carpet comfortable to walk on. This is all the more advantageous if the substrate is applied to the fabric by foaming, as in an embodiment described previously.

In a third aspect, the invention relates to a recyclable carpet according to the first aspect, manufactured according to a method according to the second aspect.

A person skilled in the art will appreciate that a method according to the second aspect is preferably configured for the manufacture of a recyclable carpet according to the first aspect and that a recyclable carpet according to the first aspect is preferably manufactured using a method according to the second aspect. Accordingly, any feature described herein, both above and below, may relate to any of the three aspects of the present invention. In the following, the invention will be described by means of non-limiting figures illustrating the invention, which are not intended to limit the scope of the invention or which should not be interpreted as such.

DESCRIPTION OF THE FIGURES Figure 1 shows a weaving pattern of a recyclable carpet according to one embodiment of the present invention. Figure 1 shows the first face of the recyclable carpet. The weft threads are inserted and interwoven in rows L with the warp threads applied along the C-C axis while an Mi weaving pattern is reproduced. The rows L of the weft threads are perpendicular to the warp threads. In the weaving pattern, a C1 warp yarn is visible on the first side of the recyclable carpet, while the warp yarn located next to the visible C1 warp yarn is covered by the weft yarn(s) and is therefore not not visible on the first side of the mat. In this example, the MI weave pattern is a plain loft. At row L' in Figure 1, no break in the weaving pattern Mi is introduced. Said weaving pattern leaves the warp thread Gt visible over a distance d indicated in figure 1. The weaving pattern MI is interrupted at the other weft rows - other than L' - so that the parts of a same warp thread remain visible. As shown in Figure 1, the parts extend over distances D different from each other and greater than the distance d determined by the weaving pattern Mi. At the level of the example illustrated in Figure 1, the pattern of weaving MI is interrupted such that the visible parts of the warp yarns on the distances D are part of the adjacent warp yarns CC, 2", Figure 2 shows a weaving pattern of a recyclable carpet according to another embodiment of the present invention.

Figure 2 shows the first face of the recyclable carpet.

The weft yarns are inserted and interwoven in rows L with the warp yarns applied along the £-C axis while an MJ weaving pattern is reproduced. The rows L of weft yarns are perpendicular to the warp yarns.

In the weaving pattern, a C1 warp yarn is visible on the first side of the recyclable carpet, while the warp yarn located next to the visible C1 warp yarn is covered by the weft yarn(s) and is therefore not not visible on the first side of the recyclable rug, In this example, the MI weave pattern is a plain weave.

At row L' in Figure 2, no break in the weaving pattern MI is introduced.

This weaving pattern leaves the warp yarn C1 visible over a distance d, as shown in Figure 2. The weaving pattern Mi is interrupted at the other weft rows - other than L' - so that the parts of the same warp thread remain visible.

As shown in Figure 2, the parts extend over distances D different from each other and greater than the distance d determined by the weaving pattern MI.

At the level of the example illustrated in figure 2, the weaving pattern MI is interrupted so that the visible parts of the warp yarns over the distances D are part of the adjacent warp yarns GC, Cv, C"' and define two seals LC1 and LEZ.

As shown in Figure 2, each joint includes portions of rows of visible chains whose distance D is either constant or variable.

Joint LC1 comprises parts of a chain row whose distance D is the same for all visible parts, while joint L£2 comprises parts of the chain row whose distance D varies from segment to segment. the other.

Figure 3 shows a weave pattern of a recyclable carpet according to another embodiment of the present invention.

Figure 3 shows the first face of the recyclable carpet.

In Figure 3, the visible parts of the warp yarns Ki can be seen as shaded areas and the visible parts of the weft yarns 11 can be seen as unshaded areas.

The weft threads are inserted and interlaced along the 1-1 axis while the warp threads are inserted along the K-K axis. The weft threads are mainly perpendicular to the warp threads.

The Haison was made in a 1-2-3-4 weaving pattern and shows a first area Z1, which is joined to a second area Z2. FIG. 3 also shows that weft 1 of the weaving pattern in zone Z2 rises to the surface more often than in zone Zi.

The average length of the frame floats obtained according to the first zone Z1 is substantially shorter than the average length of the frame floats obtained according to the second zone Z2. Furthermore, the longest frame float obtained according to the first zone Z1 is substantially shorter than the longest frame float obtained according to the second zone Z2. Consequently, the zone Z1 has a relatively low relief and the zone Z2 a relatively high relief. Also, the first longest weft float runs over seven consecutive warp threads, while the second longest weft float only runs over one warp thread. Moreover, the connection obtained according to the first zone Z1 comprises multiple weft floats which overlap at least two successive warp threads. Thus, thanks to the connection according to the first zone Z1, a section of the carpet is obtained which is higher than a section corresponding to the connection according to the second zone Z2.

Figure 4 shows a schematic representation of a cross section of a recyclable carpet according to another embodiment of the present invention.

The recyclable carpet (1) shown in Figure 4 has a vintage appearance. The carpet comprises a fabric 2 having weft yarns 3 and 3' and warp yarns 4 interlaced, in which the fabric comprises a first face 2a and a second face 2b, opposite to said first face 2a. In addition, the recyclable carpet 1 comprises a substrate 5, which comprises a first face Sa and a second face 5b, in which the first face Ba of said substrate 5 is adjacent and in contact with said second face 2b of the fabric

2.

The warp yarns 4 are yarns comprising at least 90% filament yarns. The weft yarns 3 are yarns comprising at least 30% of chenille yarns. The 3" weft yarns only include chenille yarns. The substrate 5 is essentially made of 100% polyester.

Claims (1)

1. Recyclable carpet comprising a fabric, wherein the fabric comprises a series of weft yarns inserted substantially perpendicularly into and interwoven with a series of warp yarns in one or more weaving patterns, and wherein the fabric comprises a first face and a second face opposite this first face, characterized in that the weft threads and the warp threads consist essentially of 100% polyester (PES) or recycled polyester (rPET), and that a warp comprises at least one thread and at most four threads, in which each thread comprises at least twenty-five filaments and at most seventy-five filaments. 2. Recyclable carpet according to claim 1, characterized in that at least one substrate is fixed to the second face of the fabric, in which the substrate is suitable as non-slip and in which the substrate consists essentially of 100% polyester. 3. Recyclable carpet according to claim 1 or 2, characterized in that a warp yarn has a yarn number of at least 100 dtex and at most 600 dtex. 4. Recyclable carpet according to one of the preceding claims 1 to 3, characterized in that an edge of the recyclable carpet is scalloped using a yarn essentially of 100% poivesier. 5. Recyclable carpet according to one of the preceding claims 1 to 3, characterized in that a woven strip is sewn in a U-shape on an edge of the recyclable carpet using a thread, in which the woven strip comprises weft Tis and warp consisting essentially of 100% polyester, wherein a first leg of the U-shape is on a first side of the recyclable mat, wherein a second leg of the U-shape is on a second side of the recyclable mat and wherein the yarn consists essentially of 100% polyester. 8. Recyclable carpet according to one of the preceding claims 1 to 5, characterized in that the ratio between the mass per meter of a weft yarn and the mass per meter of a warp yarn is at least 5 and of at most 15. 7. Recyclable carpet according to one of the preceding claims 1 to 6, characterized in that the weaving pattern is interrupted at least once to make visible at least part of at least one warp yarn on one of the faces of the recyclable carpet, this part having a distance D greater than the distance d of a visible warp thread in which the weft threads are inserted and interwoven with the warp threads according to this weaving pattern, and that the visible parts of the threads of warp having the distance D are grouped together at the level of at least one zone of a face of the recyclable mat and that the segments extend at different distances from each other and at distances greater than the distance d defined by the weaving pattern. 8. Recyclable carpet according to one of the preceding claims 1 to 6, characterized in that the weaving pattern has been interrupted at least once to create at least one joint, in which this joint represents a line of separation between two zones of the recyclable carpet, each having a different appearance, and a plurality of warp yarn portions, wherein these portions have a distance D which is longer than a distance d of a visible warp yarn using the weaving pattern. 9. Recyclable carpet according to one of the preceding claims 1 to 8, characterized in that the recyclable carpet comprises one or more zones having mainly upper or lower floats, thus forming a high or a low relief respectively. 10. Recyclable carpet according to one of the preceding claims 1 to 56, characterized in that the recyclable carpet comprises wide floats and narrow floats, so that the length of the wide floats is between 4 and 6 mm and the length of the narrow floats is between 1.5 and 2.5 mm. 11. A method of making a recyclable carpet, comprising: - inserting warp yarns into a weaving frame side by side without overlapping; - the insertion and weaving of the weft threads into the warp threads for the formation of a fabric such that the weft threads are arranged in successive rows essentially perpendicular to the warp threads, the weft threads being inserted repeatedly in the same way and according to one or more predetermined weaving patterns, and the fabric comprising a first face and a second face opposite this first face; characterized in that the weft threads and the warp threads consist essentially of 100% polyester (PES) or recycled polyester (rPET) and that a warp thread comprises at least one thread and at most four threads, in wherein each yarn comprises at least twenty-five filaments and at most seventy-five filaments. 12. Method according to claim 11, characterized in that the method comprises the additional step of applying a composition to the second face of the fabric for the formation of a non-slip substrate essentially of 100% polyester, the composition being a composition forming a polyester. 13. Method according to claim 12, characterized in that the composition is applied to the second face of the fabric by means of a lick roller. 14. Method according to claim 12 or 13, characterized in that the method comprises the additional step of drying the substrate at a temperature of at least 110°C and at most 170°C. 15. Method according to any one of claims 11 to 14, characterized in that the composition has a viscosity of at least 900 mPa.s and at most 2200 mPa.s and a density of at least 0.7 g/cm? and a maximum of 1.3 g/cm². 18. Recyclable carpet according to one of claims 1 to 10, manufactured according to a method according to any one of claims 11 to 15.